Sewage Treatment Plant Commissioning Process
1. Pre-Commissioning Activities
Before the actual commissioning of the wastewater treatment plant, several preparatory tasks
must be completed to ensure a smooth transition to the operational phase.
1.1. Final Inspection and Verification
• Inspect the construction: Ensure that all structures, equipment, and systems have been
built according to the design specifications. This includes checking the installation of
pumps, tanks, pipes, valves, and control systems.
• Check for any defects or unfinished work, such as issues with electrical connections,
plumbing, and instrumentation.
• Verify the integrity of the civil works: Ensure that tanks, basins, and other critical
infrastructure are free from cracks or leaks.
1.2. Documentation Review
• Review design documents: Ensure that all as-built drawings, equipment manuals, and
operation and maintenance manuals are available and correct.
• Check safety plans: Verify that all safety equipment and protocols are in place,
including emergency shutdown systems, alarm systems, and PPE (Personal Protective
Equipment) for operators.
1.3. Training of Operators
• Operator training: Provide hands-on training to operators and staff who will run the
facility. This training should cover all operational aspects, including the handling of
equipment, troubleshooting, and emergency procedures.
• Safety protocols: Ensure operators are well-versed in safety standards and protocols.
2. System Startup
This is the phase where individual components and systems are started up to verify their
functionality before the plant is fully operational.
2.1. System Testing
• Start-up of utility systems: Power, water supply, air supply, and gas supply systems
should be tested first.
• Testing of individual components: Each treatment process unit (e.g., aeration tanks,
clarifiers, filtration units) must be tested for functionality.
• Check flow paths: Ensure that the entire flow path, from influent (incoming
wastewater) to effluent (treated water), is intact and working as expected.
2.2. Mechanical Systems Check
• Pumps and motors: Start the pumps and motors and check for operating parameters,
such as voltage, pressure, and flow.
• Valves: Verify that valves and gates are operating correctly. Test for proper opening
and closing.
2.3. Electrical Systems Check
• Control panels: Verify the functionality of control panels, electrical wiring, and
connections.
• Instrumentation: Ensure that sensors, flow meters, level indicators, and chemical
dosing systems are calibrated and functioning properly.
2.4. Automation
• Automation systems: Ensure that the system is properly connected and can control all
functions of the plant, including alarms.
3. Process Commissioning
In this phase, the treatment processes and operational testing are carried out to ensure that each
treatment stage is functioning as expected.
3.1. Introduction of Influent
• Start feeding wastewater into the system (atleast 80% of the daily capacity) to allow
the system to adjust to the flow and load conditions. This helps to prevent overloads or
system shocks that could damage equipment or cause treatment inefficiencies.
• Monitor influent quality: Check influent water quality to ensure it meets the expected
characteristics for each treatment unit.
3.2. Testing of Treatment Units
• Preliminary tests of aeration units: Test the aeration tanks and adjust airflow and
oxygen levels to support microbial growth for effective biological treatment.
• Filtration tests: Check the performance and verify that filters are removing solids and
particulate matter correctly.
• Disinfection units: Test disinfection units such as chlorination systems to ensure they
meet the required disinfection standards.
3.3. Daily Activities
• Management, monitoring and operation of the whole treatment process and operation
of the existing system.
• Provide Trouble shooting of equipment, controls, valves, etc. any time of the day if
needed.
• Stationary Operator on site with 24 hours of duty daily. (shifting schedule)
• Record parameters that are available to test on site such as PH and Sludge Volume.
• Check STP blower conditions (i.e. fan belt, oil level, sound and pulley motor
performance, ampere, wattage, and voltage levels);
• Check motor control center (MCC).
• Check and clear off debris and solid wastes materials that can clog the system and
hamper smooth operation. Bar screen should be free from solid wastes at all time to
avoid overflow;
• Check pumps and clear clog nozzle, if applicable.
• Check submersible pumps and level controls.
• Regulate chemical dosing.
• Always assure the area environmentally clean.
• Notify the on-duty owner building engineer or the PCO for any minor or major
breakdown and other incidents that might affect the operation of the STP. This must be
followed by a formal written report with recommendation;
• Conduct monthly audit of the system and prepare inventory for the status and condition
of the equipment. Submit assessment and monthly report for the info and reference of
the owner.
• Monitor process parameters: As the plant starts handling full load, continue
monitoring dissolved oxygen levels, sludge concentrations, and other key parameters.
• Adjust chemical dosing: If chemical treatments (e.g., coagulants, flocculants) are
used, adjust the dosing rates to optimize performance.
4. Performance Testing and Validation
Once all systems are operational, a more formal series of tests will be conducted to ensure the
plant meets the designed performance criteria.
4.1. Performance Testing
• Run full-scale tests: Test the plant at full capacity, simulating peak wastewater loads
to validate the system's ability to handle such conditions.
• Monitor effluent quality: Ensure that the effluent meets regulatory discharge
standards for parameters such as BOD (Biochemical Oxygen Demand), TSS (Total
Suspended Solids), COD (Chemical Oxygen Demand), pH, and other relevant
indicators.
• Effluent quality compliance: Confirm that the effluent is being treated to the required
level, whether it’s being discharged directly into the environment, into a receiving water
body, or recycled.
4.2. System Integration Testing
• Check integration: Ensure that all systems, including pumps, valves, and
instrumentation, are properly integrated and functioning together.
• Verify automation: Test automatic control and shutdown procedures. The system
should respond appropriately to changes in flow, pressure, or any abnormal conditions.
4.3. Final Adjustments
• Make any necessary adjustments to equipment or processes to optimize performance
based on the performance tests. This may include adjusting flow rates, chemical dosing,
or aeration levels.
5. Handover and Documentation
After successful commissioning, the plant will be handed over to the operating team, and
detailed documentation should be provided.
5.1. Handover to Operations
• Formal handover: The plant is handed over to the operation and maintenance team
for full operation.
• Training: Ensure operators have received comprehensive training on all aspects of the
plant’s operation, including routine tasks, emergency procedures, and troubleshooting.
5.2. Final Documentation
• As-built drawings: Provide final, detailed as-built drawings of the system, which
include all equipment specifications and system layout.
• O&M Manual: Provide operation and maintenance manuals for all equipment and
systems, including recommended maintenance schedules, spare parts lists, and
troubleshooting guides.
• Performance reports: Provide a report on the commissioning process, including test
results, any issues encountered, and how they were resolved.
5.3. Performance Monitoring Period
• Post-commissioning monitoring: There is often a period of post-commissioning
monitoring (typically 60-90 days) where the system’s performance is continually
monitored to ensure it is operating within expected parameters.
• Adjustments: If any issues arise during the post-commissioning period, necessary
adjustments will be made.
6. Final Acceptance
After the successful completion of all tests and adjustments, and after ensuring compliance
with regulatory standards, the wastewater treatment plant is officially accepted as operational.
Summary of Key Steps in Commissioning:
1. Pre-commissioning checks (construction verification, training, documentation
review).
2. System startup (testing utilities, mechanical systems, and electrical systems).
3. Process commissioning (gradual introduction of influent, optimization of treatment
processes).
4. Performance testing (full-scale tests, effluent quality validation).
5. Handover and documentation (final report, O&M manuals, training).
The commissioning process is essential for ensuring that a wastewater treatment plant operates
effectively, safely, and in compliance with environmental regulations. Proper commissioning
allows the plant to be operated with confidence, ensuring long-term performance and
reliability.
STP OPERATIONS AND MAINTENANCE WORK SCHEDULE
FREQUENCY
SCOPE OF WORK
NO. DAILY MONTHLY QUARTERLY ANNUALLY
DOSING OF BACTERIA / RELEASING
1
ENZYME (If necessary)
DOSING OF CHEMICALS AND
2
CHLORINE
3 CHANGE OIL
4 BELT REPLACEMENT
CHECKING/TROUBLESHOOTING OF
5
CONTROL PANEL (MCC)
MONITORING, AND CHECKING OF
6
EQUIPMENT
7 CLEANING OF BAR SCREEN
